Blanks for vehicle bumpers



Nov. 28, 1967 P. R. OBRIEN 3, w

BLANKS FOR VEHICLE BUMPERS Original Filed Oct. 26. 1960 15 Sheets-Sheet 1 INVENTOR PAUL R. O'BRIEN HIS ATTORNEY Nov. 28, 1967 r r P. R. O'BRIEN 3,355,266

7 BLANKS FOR VEHICLE BUMPERS Original Filed Oct. 26. 1960 15 Sheets-Sheetv 2 mvsuyon PAUL R. OBRIEN BY %W 54 ms ATTORNEY5 NOV. 28, 1967 o- 3,355,266

- BLANKS FOR VEHICLE BUMPERS Original Filed Oct. 26, 1960 15 Sheets-Sheet 35 x INVENTOR My /d PAUL ROBRIEN VA M . HIS ATTORNEYS 2 1967 P. RQO-BRIE 3,355, 6

BLANKS FOR VEHICLE BUMPERS Original Filed Oct. 26, 1960 15 Sheets-Sheet 4 A b Y EEE C LOGS GUT E 1:5 6 mm HGAOGENIZED INTO B'LLETS LOGS I; J BILLETS Q HEATED H l J K L M OUT INTO H4 BF onmme EXTRUDED BLANKS TREATMENT 29 N 0 o' P QUENOH TRM 5%; BRACKETS ARTIFICIAL e. IF usso AGING I SHAPE ENDS Q R S POLISH ANODIZE BUFF DIP FIG.56

INVENTOR PAUL R. O'BRIEN HIS ATTORNEYS Nov. 28, 1967 P. R. OBRIEN 3,355,266

BLANKS FOR VEHICLE BUMPERS Original Filed Oct. 26, 1960 15 Sheets-Sheet 5 INVENTOR PAUL ROBRIEN Em i401 )wo HIS ATTORNEYS Nov. 28, 196 7 OBRIEN 3,355,266

BLANKS FOR VEHICLE BUMPERS HIS ATTORNEYS Nov. 28, 1967 P. R. O'BRIEN 3,355,266

BLANKS FOR VEHICLE BUMPERS Original Filed 001;. 26, 1960 7 l5 Sheets-Sheet 7 232, fzsz ,2 FIG.37

INVENTOR PAUL ROBRIEM 2L .7 7 BY 2%! 144% FIG. 39 I HIS ATTORNEYS Nov. 28, 1967 P. R. O'BRIEN 3,355,266

BLANKS FOR VEHICLE BUMPERS Original Filed Oct. 26, 1960 15 Sheets-Sheet s INVENTOR PAUL R. O BRIEN BY I 271%.,

HIS ATTORNEYS Nov. 28, 1967 P. R. O'BRIEN 3,355,266

BLANKS FOR VEHICLE BUMPERS Original Filed Oct. 26, 1960 15 Sheets-Sheet 9 #32 20 I 204 f f 424 FIG.48V

mvzm'pn PAUL R. o amen HIS ATTORNEYS NOV. 28, 1967 p, O'BRIEN 3,355,266

BLANKS FOR VEHICLE BUMPERS Original Filed Oct. 26, 1960 15 Sheets-Sheet 10 HIS ATTORNEYS Nov. 28, 1967 P. R. O'BRIEN 3,355,266

BLANKS FOR VEHICLE BUMPERS 7 Original Filed Oct. 26, 1960 15 Sheets$heet 12 FIG.6|

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V224 INVENTOR 450 PAUL R.- OBRIEN Z4! 25:? 21]]; BY 44 Hus ATTORNEYS Nov. 28, 1967 P. R. O'BRIEN BLANKS FOR VEHICLE BUMPERS 15 Sheets-Sheet 15 Original Filed Oct. 26, 1960 INVENTOR. PAUL R. O'BRIEN av ZM ATTORNEYS FIG. 65

Nov. 28, 19 67 P. R. O'BRIEN BLANKS FOR VEHICLE BUMPERS l5 S heetsSheet 14 Original Filed Oct. 26. 1960 y v V INVENTOR.

PAUL R. O'BRIEN h2 4 ATTORNEYS FIG. 66

FIG. 58

' Nov. 28, 1967 R 'BR 3,355,266

BLANKS FOR VEHICLE BUMPERS Original Filed Oct. 26, 1960 I 15 Sheets-Sheet 15 INVENTOR. PAUL R. O'BRIEN HIS ATTORNEYS United States Patent Qfiiice 3,355,256 Patented Nov. 28, 1957 BLANKS FOR VEHICLE BUMPERS Paul R. OBrien, Chesterfield County, Va., assignor to Reynolds Metals Company, Richmond, Va., a corporation of Delaware Original application Oct. 26, 196i), 821'. No. 65,138, new Patent No. 3,212,941, dated Oct. 19, 1965. Divided and this application Aug. 26, 1965, Ser. No. 482,839

10 Claims. (CI. 2919()) This application is a division of applicants copending application, Ser. No. 65,138, filed Oct. 26, 1960, now Patent No. 3,212,941, for Aluminum Article, Such as a Bumper and the Like, which copending application is, in turn, a continuation-in-part of applicants application, Ser. No. 25,689, filed Apr. 25, 1960, now abandoned for Aluminum Article, Such as a Bumper and the Like.

This invention relates to the production of brilliant surface aluminum containing metallic articles, and more particularly to the production of bumpers for automotive vehicles, such as automobiles and the like, which bumpers are formed from aluminum containing metallic substances. The invention also relates to other articles, such as strips for dashboards, structural members of the automobile, frames, etc., which are used both for stiffness and structural characteristics as well as decorative trim.

Automotive vehicle bumpers have been made by forming sheet steel of relatively uniform thickness into the desired shape in various presses and the like. Thereafter the bumpers so formed have been chrome plated to the desired chrome thickness and brightness. These bumpers have undesirable disadvantages. For example, such bumpers do not have the necessary strength along the area where extra strength is needed. Also such steel bumpers are relatively heavy and have an undesirable weight effect at the ends of the car, and particularly when subjected to the salt splash from salted highways.

According to this invention, automobile bumpers and the like are made from aluminum containing metallic material in a manner so that such aluminum bumpers have from two to six times the impact and load capacities of steel bumpers. The cost ratio is favorable to the aluminum bumpers, and with proper product design may be as much as about a five to seven ratio. In addition the thickness of the material may be increased where most needed, such as at the upper and lower edges where tow chains may create a bending action, and also at the impact bead at the outermost zone of the bumper. Also the aluminum containing bumper will not corrode and will not lose its brightness in the manner of a steel bumper.

The article or bumper of this invention is made of an aluminum containing metallic substance such as an aluminum heat treatably alloy, preferably a magnesium alloy, which may be, for example, a wrought aluminum alloy of the series containing aluminum alloy 6463-T6 or a similar alloy.

- The bumper of this invention overcomes many of the objectionable features of sheet steel bumpers which are now in use.

The thickness of the material is increased at the impact ridge where impacts are most likely and at the edges of the bumper. This produces a beam-like action which strongly resists bending during impact, towing, pushing, etc.

The bumper of this invention has approximately /2 the weight of a sheet steel bumper of comparable size and strength. The cost ratio is also very favorable. The tooling cost is approximately /2 that of tools for comparable steel bumpers. It does not corrode materially and does not lose its brightness.

The novel manufacture of this invention includes novel apparatus and methods for eflicient production of the bumper.

The operation includes a combined formation and heat treatment that gives greater physical strength, improved properties and increased specularity or reflectivity.

Accordingly, it is an object of this invention to provide an improved bumper made of metallic substances which contain a large proportion of aluminum.

Another object is to provide improved apparatus for producing such a bumper.

Another object of this invention is to provide brilliant surface aluminum containing metallic articles, such as automotive vehicle bumpers and the like, which are made of aluminum containing metallic substances.

Another object of this invention is to provide aluminum containing bumpers in which the thickness of the material is increased where most needed.

Further objects are apparent from this description and from the accompanying drawings, in which:

FIGURE 1 is a diagrammatic representation of a typical extrusion operation for this invention.

FIGURE 2 is a diagrammatic representation of a typical blank cut from the extrusion of FIGURE 1.

FIGURE 3 is an enlarged cross section along the line 33 of FIGURE 2.

FIGURE 4 is a diagrammatic representation of an apparatus in which the brilliant surface enhancing medium may be applied.

FIGURE 5 is a diagrammatic representation of die construction for the first forming operation.

FIGURE 6 is a diagrammatic representation of a portion of the blank after the first forming operation.

FIGURE 7 is a cross section along the line 77 of FIGURE 6. I

FIGURE 8 is a diagrammatic representation of the end of the blank after the first forming operation.

FIGURE 9 is a diagrammatic representation of a die construction for a second forming operation.

FIGURE 10 is a diagrammatic representation of a portion of the blank after the second forming operation.

FIGURE 11 is a cross section along the line 1111 of FIGURE 10.

FIGURE 12 is a diagrammatic representation of a die construction for a third forming operation.

FIGURE 13 is a diagrammatic representation of a portion of the blank after the third forming operation, and piercing operation.

FIGURE 14 is a diagrammatic representation of the quenching operation following the forming procedure.

FIGURE 15 is a diagrammatic representation of the trimming and piercing operations following the quenching operation.

FIGURE 16 is a diagrammatic representation of the precipitation heat treatment for artificial aging.

FIGURE 17 is a diagrammatic representation of the polishing and butting operations following the aging operation.

FIGURE 18 is a diagrammatic representation of the bright dip operation following the polishing and butfing operation.

FIGURE 19 is a diagrammatic representation of the anodizing operation following the bright dip operation.

FIGURE 20 is a diagrammatic representation of the finished bumper part in readiness to be installed on the automobile.

FIGURE 21 is a diagrammatic representation of a portion of the article of FIGURES 1-20 in use on the automobile.

FIGURE 22 is a diagrammatic perspective viewof another embodiment of a bumper according to this invention.

FIGURE 23 is a cross section of the extrusion for the bumper of FIGURE 22.

FIGURES 24 and 25 are cross sections of the blank taken along the lines 24-24 of FIGURE 28 and 25-25 of FIGURE 29 respectively.

FIGURE 26 is a view in perspective of the license plate area after the forming, trimming and piercing operations.

FIGURE 27 is a cross section along line 27-27 of FIGURE 26.

FIGURE 28 is a perspective view looking toward the top edge of the end of the bumper after the second draw operation prior to cupping the end.

FIGURE 29 is a perspective view looking toward the bottom edge of the bumper after cupping the ends but before trimming.

FIGURE 30 is a perspective view looking toward the top edge of the finished bumper.

FIGURE 31 is a chart indicating steps which may be performed for the production of the bumper.

FIGURE 32 is a diagrammatic elevation, partly in cross section, of an apparatus for bending the ends of a bumper formation or blank, which blank is shown in initial position in the apparatus.

FIGURE 33 is a view of a portion of FIGURE 32 showing the parts during an early stage of the forming or bending stroke.

FIGURE 34 is a view of the part of FIGURE 33 at the end of the stroke.

FIGURE 34A is a cross section along the line 34A- 34A of FIGURE 34.

FIGURE 35 is a horizontal cross section along the line 35-35 of FIGURE 32, with the blank removed.

FIGURE 36 is a cross section along line 36-36 of FIGURE 34.

FIGURE 37 is a cross section along the line 37-37 of FIGURE 32.

FIGURE 38 is a cross section along the line 38-38 of FIGURE 33.

FIGURE 39 is a diagrammatic elevation of the front of a press having a pair of duplicate bending apparatus of the character shown in FIGURES 32-38 inclusive.

FIGURE 40 is a perspective view which shows the bumper blank in dotted lines before it has been processed in the apparatus shown in FIGURES 3239 and in full lines after it has been processed by such apparatus.

FIGURE 41 is a cross section along the line 41-41 of FIGURE 40.

FIGURE 42 is a cross section along the line 42-42 of FIGURE 40.

FIGURE 43 is a cross section similar to FIGURE 37 showing another embodiment of the gripping means for the end of the bumper blank in the rocker member.

FIGURE 44 is a cross section along line 44-44 of FIGURE 43.

FIGURE 45 is a plan view of a substantially completed bumper, with parts broken away.

FIGURE 45A is a modification applicable to both ends of the bumper of FIGURE 45.

FIGURE 46 is an enlarged cross section of the immediate structure along the line 46-46 of FIGURE 45.

FIGURE 47 is a cross section along the line 47-47 of FIGURE 45.

FIGURE 48 is an elevation of a portion of FIGURE 45 taken from the line 48-48 of FIGURE 45.

FIGURE 49 is a cross section of another embodiment of a bumper and attaching bracket.

FIGURE 50 is an elevation showing another embodiment of adjacent ends of a rocker member and the center pressure member.

FIGURE 51 is a diagrammatic horizontal cross section of one symmetrical half of another embodiment of this invention showing the initial position in dotted lines and a second position in full lines.

FIGURE 52 is a vertical cross section along the line 52-52 of FIGURE 51.

FIGURE 53 is a diagrammatic horizontal cross section, on reduced scale, showing a position following the full line position of FIGURE 51.

FIGURE 54 is a cross section along the line 54-54 of FIGURE 53, on enlarged scale.

FIGURE 55 is a cross section along the line 55-55 of FIGURE 54.

FIGURE 56 is a vertical view of another embodiment for the rocker members of FIGURE 43.

FIGURE 57 is a view of a portion of FIGURE 56 at a later stage of the strike.

FIGURE 58 is a transverse view of FIGURE 57 taken along the line 58-58 of FIGURE 56.

FIGURE 59 is a view of the bend of a bumper and indicating the advantages of the steps of FIGURES 56- 58.

FIGURE 60 is a cross section of another embodiment of rocker member construction.

FIGURE 61 shows the rocker member of FIGURE 60 with the punch member and cam member.

FIGURE 62 is a side elevation of FIGURE 60.

FIGURE 63 is a diagrammatic enlarged vertical cross section of the dies of FIGURE 12 taken along line 63-63 of FIGURE 64.

FIGURE 64 is a cross section transverse to FIGURE 63.

FIGURE 65 is an enlarged diagrammatic typical cross section along the end of the finished bumper construction, substantially along line 65-65 of FIGURE 64.

FIGURE 66 is an enlarged view similar to FIGURE 65 but taken along line 66-66 of FIGURE 64.

FIGURE 67 is a longitudinal cross section of part of the blank of FIGURE 63 after the strike and trimming operations and taken along the plane of FIGURE 63.

FIGURE 68 is a reduced view of the upper die of FIGURES 63 and 64.

FIGURE 69 is a view in perspective of another embodiment of a bumper according to this invention.

FIGURE 70 is an enlarged cross-section taken along the line 70-70 of FIGURE 69.

FIGURE 61 is a cross-section of a portion of a bumper somewhat similar to the bumper of FIGURES 69 and 70 but showing another embodiment of the insert.

FIGURE 72 is a cross-section of the parts of FIGURE 71 before assembly.

Certain words indicating direction and the like, such as bottom, top, above, below, etc., are used for convenience in description, and are not intended to imply that the invention is limited to the specific directions so described.

According to this invention, a proper aluminum containing metallic substance, preferably in the alloy form, such as an alloy known as number 6463, is formed into a brilliant surface aluminum containing metallic article, such as an automotive vehicle bumper and the like by the operations which are outlined in FIGURE 31 as illustrative of the practice of the invention as follows:

(1) The alloy is cast at A into logs B such as from 6 inches to 14 inches in diameter DC.

(2) The logs are homogenized at C such as in a 33 hour cycle of which 24 hours may be a temperature soak in an air atmosphere at a temperature in the order of 1100 to 1150 F. This step is important in removing irregular streaked colored surfaces known in the trade as structural streaking. This is an important step in the process for obtaining maximum specularity. The homogenizing time cycle, including the soaking temperature, may vary from 18 to 48 hours depending upon the particular material being treated.

(3) The logs are cut at E to proper length to form billets F for use in proper extruding apparatus.

(4) The billets are heated to extruding temperature at G.

(5) The billets F are extruded at H in proper apparatus to form a strip I of the desired shape, which shape may be, for example, any of the shapes of the blanks for bumper formation herein disclosed.

(6) The strip I is then cut at I into blanks K of substantially the length of the article being produced, with suflicient additional material to provide for procedure losses.

(7) The blanks K are heated to a temperature in the order of 935 to 980 F. in furnace L. They are soaked in furnace L for a maximum period of time (such as five to fifteen minutes) in an atmosphere of air and ammonium fluoborate (NI-I BE and the like. For example, one ounce of ammonium fluoborate to 48 cubic feet of furnace capacity may be introduced into the furnace L in sufficiently comminuted form to be taken up by the air which is forcibly circulated in the furnace L by a suitable fan or blower.

The ammonium fluorborate reacts with the aluminum in the blank K to form a preferred type of oxide which is believed to be a complex aluminum fluoborate coating.

The aluminum ammonium fluoroborate coating prevents attack of the surface by a gas such as hydrogen which would otherwise result in a non-uniform attack of the surface and, therefore, result in a blotchy appearance. However, with this complex coating, a uniform and brightening attack of the surface is later made by the chemical-brightening composition. This is particularly true of aluminum containing magnesium alloys.

This atmosphere is illustrative of any desired brilliant surface forming medium or hydrogen absorption resistance producing medium.

(8) Within to 45 seconds time interval after the operation 7 above, the blank K is subjected to forming procedure which may include one or more forming procedures diagrammatically illustrated at M in FIGURE 31.

The illustration at M is emblematic of any of the various forming procedures herein disclosed, or similar forming procedures according to this invention.

(9) After the desired number of forming operations, the article or bumper is quickly quenched substantially to room temperature, such as in a violent air agitation or in a water quench, as diagrammatically indicated at N, FIGURE 31.

(10) The article or bumper is then trimmed and pierced at 0, FIGURE 31, to the desired final shape in proper apparatus. For example, the area which receives the license plates in a bumper construction may be simultaneously pierced at a plurality of points such as shown in FIGURE 13 by the die member shown in FIGURE which figures are merely illustrative of the trimming and piercing operations which are or may be performed on the article and in any of the embodiments herein disclosed. The brackets are attached at O.

(11) The article may then be artifically aged at P, in FIGURE 31, such as by a precipitation heat treatment, as in a furnace at a temperature of 360 F. for four to six hours or at 375 F. for from two and one-half to three hours to produce the desired temper, such as a T6 temper. This treatment is also diagrammatically indicated in FIGURE 16.

(12) If desired, smoothing operations, such as suitable polishing and/or buifing operations, may be performed at Q, FIGURE 31, on the exterior surface of the article where desired, as also is diagrammatically indicated in FIGURE 17.

(13) If desired, the article may ened at R, FIGURE 31, and as also diagrammatically indicated in FIGURE 18 in any well known chemical brightening solution. For example, one suitable commercially available chemical brightening solution contains about 81% phosphoric acid, 3% nitric acid, and the be chemically brightremainder water. The solution may be maintained at an operating temperature of about F.

Thereafter, the article may be annodized at 8 in FIG- URE 31 and as also diagrammatically indicated in FIG- URE 19, in any well known anodizing solution, to produce an aluminum oxide film of from .00015 to .0003 inch in thickness.

Describing in more detail the operations of FIGURES 1 to 19, which relate to one embodiment of this invention, the specific article illustrated for the purpose of illustration is a part of the rear bumper of a 1959 Pontiac automobile, modified according to this invention. The extruding apparatus 22, FIGURE 1, or H in FIGURE 31, extrudes a relatively long strip 24 of FIGURE 2 or I of FIGURE 31, by well known process, which may include the operations 1 to 5 above and steps A-I FIG- URE 31. The blank 26, FIGURE 2 or I FIGURE 31, may be cut to length at I, FIGURE 31, as above described for operation 6, or the blank may be produced after a light stretching operation.

The cross section of the strip 24, and/or blank 26 is indicated in FIGURE 3. The thickness of the material may be increased where most needed, such as at the edges 28 and 3t) and at the outward impact curve 32. For example, the thickness at edge 28 may be .240 in vertical measurement. The thickness of edge 30 may be .260 inch in vertical measurement. The thickness of curve 32, at its thickest point, may be .281 inch in thickness, measured along the radial line 34, where such radial line 34 intersects at the thickest portion of the curved part 32. The typical thickness of the main portion of the wall may be .110 inch, for example, at a place such as 36 in FIGURE 3. By way of example, the dimension of A may be 10.532 inches. The dimension B may be 3.750 inches. The dimension C may be 3.188 inches. The dimension D may be 3.906 inches, and the other dimensions may be substantially in the general ratio indicated in FIGURE 3.

The blank shown in FIGURES 2 and 3 may soak in the furnace 37, FIGURE 4, or L, in FIGURE 31, for a period of from five (5) to fifteen (15) minutes in an atmosphere of air into which ammonium fluoborate has been added. This substance may be introduced in solid or comminuted form, if desired, into the furnace 37, or to where such substance vaporizes and mixes with the circulated air in the furnace 37 or L to form a brilliant surface enhancing medium, or a hydrogen absorption resistance producing medium, which is particularly beneficial in enhancing the effectiveness of the chemical brightening and anodizing operations which are later performed on the article, and in preventing hydrogen absorption during the entire manufacturing operation which follows.

A forming procedure is then performed on the blank within about 10 to 45 seconds after the soaking operation in the furnace 37. The following procedure may include one or more forming operations. For example, a first forming draw is performed while the blank is still within about from 900 to 950 F., as diagrammatically indicated in FIGURES 5 to 7, and possibly FIGURE 8. FIGURE 5 is a diagrammatic representation of any drawing die construction which will produce the preliminary license plate receiving indention 38, FIGURE 6, in blank. The diagrammatic illustration in FIGURE 5 is merely to indicate that a pair of relatively movable die members 40 and 42 may be operated by a suitable press, in a well known manner, to produce the indentation 38. The dies 40 and 42 preferably are heated to a temperature of 350 to 400 F.

A second forming operation may be performed while the blank is still at a temperature of from 850 to 900 F., as diagrammatically illustrated in FIGURES 9, l0 and 11. The die members diagrammatically indicated at 44 and 46 are relatively movable towards and away from each other by a suitable press as heretofore described in connection with FIGURE 5. It performs a second draw on the indentation 38 of FIGURES -6 and 7 so that the walls 48 are substantially perpendicular to the general longitudinal axis of the bumper and are bounded by the ridges 50 which are rigidifying and ornamental in nature. The dies, 44 and 46 preferably are also heated to a temperature of 350 400 F. This second draw may substantially finish the indentation 38 to its desired shape so that it will be in readiness for the trimming and piercing operation which will be performed later. In addition, this second forming operation may alter the inner contour of the cross section throughout the length of the blank, for example, as indicated along the cross section 52, FIGURE 11, and may form head 20, of FIGURE-3, on both sides of the license plate indentation 38. The license plate receiving wall 54 has now been formed substantially at right angles to the other wall 56.

If desired, a third forming operation may be performed by a pair of dies diagrammatically indicated at 58 and 60 in FIGURE 12 which bend the end portion of the blank at 62 in the direction of the spaced edges 28 and 30, as shown in FIGURE 8, if not previously formed, so that this part may be later trimmed and pierced. The end portion 62 later will cooperate with the additional portions 64 of the bumper construction on the car, as illustrated in FIGURE 21, to form a neat seam 66 and a strong junction at this point as will become apparent to those skilled in the art. This third forming operation may be performed while the blank is still at a temperature of from about 800 F. to 850 F. The dies 58 and 60 preferably are heated to a temperature of 350400 F.

Thereafter, the blank, while still in a heated condition, and as soon as possible after the last forming operation, may be quenched as diagrammatically indicated by FIG- URE 14, and N of FIGURE 31, in a water bath 67, or in a violent air agitation apparatus or Water spray, not shown.

After the quenching operation, the blank may be trimmed and pierced where required, as diagrammatically indicated in FIGURES 13 and 15 to produce piercings 70, 72, 74, 76 and any other desired trimming or piercing operations which may be necessary.

After the piercing and trimming operation, the blank may be artificially aged such as by a precipitation heat treatment to produce the desired temper, such as a T6 temper. This may be done in any well known manner, as, for example, in a furnace shown in FIGURE 16, or at P, FIGURE 31, wherein the air atmosphere is maintained at a temperature of from 360 F. to 375 F., as previously described. This artificial age treatment may be at the temperatures and for the periods of time heretofore given.

Thereafter the exterior surf-aces of the blank or bumper may undergo a smoothing treatment such as a polishing and bufiing treatment by any suitable apparatus, FIGURE 17 and Q of FIGURE 31, of which FIGURE 17 is merely a diagrammatic representation.

Thereafter the article may be chemically brightened, for example, in the tank 82, FIGURE 18 or R, FIGURE 31, in any desired commercial chemical brightening solution.

Thereafter the article may be anodized, for example, as indicated at 8, FIGURE 31, or in the tank construction 84 of FIGURE 19 to which the electrical leads 86 and 88 from the current source 90 may be connected respectively to the cathode which may be the tank wall, if desired, and to the anode, which may be the bumper, to produce an oxide film of the thickness heretofore disclosed.

The finished article is then in the form as shown in FIGURE 20 in readiness to be installed on an automobile to cooperate with the other part 64 of the bumper, as shown in FIGURE 21, to which it is attached by bolts passing through bolt holes 76, FIGURE 20 with the channel open portion formed by the edges 28 and 30 of the bumper directed toward the vehicle and the channel bottom 26 directed away from the vehicle.

To illustrate the application of this invention to another 8 type of bumper, reference is now made to FIGURES 22 to 30.

FIGURES 22-30 show another embodiment of this invention as applied to another type of bumper, such as the rear bumper of the Ford 1959 automobile, modified according to this invention.

FIGURE 22 illustrates the finished bumper diagrammatically in use on the automobile. Some of the differences of this bumper, as compared to the Pontiac automobile bumper of FIGURES 1-21, are that the upper edge of this bumper is curved downwardly at to accommodate the lights 102, and that the ends 104 are integral and are curved around the rear corner of the car at 106, so the ends 104 are forwardly directed along the side of the car. The edges 108 of these ends 104 are inwardly cupped, so they do not present an exposed forward sharp edge.

The extrusion may be similar to that of FIGURES 1 and 2, but may have a cross section as shown in FIGURE 23, where the edges are thicker at 110 and 111, and the part most likely to be bumped is thicker at 114. In general, the thicknesses given in connection with FIGURE 3 may be approximately the same in FIGURE 23, but the overall dimensions A to D may be varied to fit the particular automobile to which the bumper is to be applied, such as the 1959 Ford automobile.

The extrusion may be cut to length similarly to FIG- URE 2 and the blank thus formed may be heated to the same temperature and may be soaked in a furnace, such as in FIGURES 4 or 31, in the same air and ammonium fiuoborate medium and for the same length of time.

Thereafter the blank may have a forming procedure which may include one or more drawing operations, similar to those described in connection with FIGURES 5-11 to form the license plate receiving area, as shown in FIG- URES 26 and 27 with the license plate area being shown in trimmed condition in FIGURE 26.

The light receiving downward curve 100 of FIGURES 22 and 28 may be produced by a drawing operation which produces the curve as shown at 100 in FIGURE 28 and which may leave the excess material 116 to be trimmed.

The ends of the bumper blank are first bent around by a suitable forming operation, as indicated at 118, FIG- URE 28, and are then cupped inwardly as at 120, FIG- URE 29, where the ragged edges 112 may later be trimmed.

All of these forming operations are performed within about 10-45 seconds of time after the treatment in the furnaces of FIGURES 4 or 31, while the blank is still at a temperature of about from 950 to 800 F.

Thereafter the formed blank may be quenched to room temperature in a violent air agitation or in a water dip or spray quench as diagrammatically illustrated in FIG- URES 14 and 31.

Trimming and piercing may then be performed with dies of proper shape, such as diagrammatically illustrated in FIGURE 15, or at O in FIGURE 31, but shaped to produce the proper trimming and piercing operations required for the particular bumper involved, such as the rear bumper of the 1959 Ford.

Artificial aging, such as precipitation heat treatment, at the temperatures and lengths of time previously given, may then be performed in a furnace, for example, as diagrammatically illustrated in FIGURES 16 or 31. Polishing and buffing, as diagrammatically illustrated in FIG- URES 17 or 31, may be applied to the desired areas by proper polishing and butting tools suitable for those areas. Chemical brightening and anodizing, as in FIGURES 18, 19 and 31 may then be performed to produce the finished bumper of FIGURES 21 and 30.

The bumper may be applied to the car by proper bolts through openings 123.

FIGURES 32 to 50 inclusive illustrate another embodiment of this invention which is exemplified, for example, in the 1959 Buick rear bumper, modified accord- 2 ing to this invention, and which is used to illustrate features of this embodiment.

FIGURES 40-42 and 45-48 show the modified 1959 Buick rear bumper in various stages of production.

FIGURES 32-39, 43 and 44, show an apparatus and method for bending a straight blank 200, such as shown in dotted lines in FIGURE 40 into the shape shown in full lines at 292 in FIGURE 40.

The straight, dotted line, blank 260 of FIGURE 40 previously has been cast, extruded, cut, heated, and soaked in an atmosphere of air and NFL, or the like, in a manner similar to the steps described in connection with FIG- URES 1-30 or according to steps A-L, inclusive of FIG- URE 31. The metallic material may be of the character herein elsewhere specified, and for example may be an aluminum alloy of the character known as the 6364 series.

The blank 26% of FIGURE 40 preferably is substantially within a temperature range in the order of from 935-980 F. when it leaves furnace L of FIGURE 31 and is introduced into the apparatus of FIGURES 32-39, 43 and 44. It is formed and bent into the shape shown in full lines 262, FIGURE 40, within about 10 to 45 seconds. The formed or bent blank 262 is then immediately quenched substantially to room temperature in a violently circulating air quench or a water quench, as diagram matically illustrated at N in FIGURE 31. Thereafter suitable steps are performed on the quenched blank 262, such as indicated at -8 in FIGURE 31 to finish the blank 262 into a substantially completed bumper.

An advanced stage in the completion of the bumper is shown in FIGURES 45-48, and a cross section of another embodiment is shown in FIGURE 49.

The general cross section of the blank 260 and 202 is substantially as shown in FIGURE 41. The blank may be channel shaped with two longitudinal, spaced edges 280 and 282 and a longitudinal channel bottom 442 and with extra thickness in one or more bend resisting zones such as at edges 28!) and 282 and at channel bottom 442. The edges 280 and 282 are to be directed toward the vehicle and the bottom 442 is to be directed away from the vehicle when the bumper which is made from the blank is attached to the vehicle. An indented portion 204 of FIGURES 40 and 42 is also formed in the blank 202 while in the apparatus of FIGURES 32-39, 43 and 44. This indented portion 204 is later finished into a tail light window 266 which is shown in FIGURES 45 and 48. A suitable transparent plate, not shown, is secured in the window 206, FIGURES 45-48, on the flanges 208 by suitable bolts, not shown, which pass perpendicularly through the notches 210 in the window 266.

The original straight blank 2% and the bent blank 262 of FIGURE 40 has excess material 209 at its ends, which later is removed approximately at 211 during the steps indicated at 0-8, FIGURE 31, and the remaining portions 212 of the bent ends, and the central straight portions 214 of the bent blank 262, FIGURE 40, are finished into the shaped ends 216, central portion 218, and window 266 of FIGURES 45-48.

Reference now is made to FIGURES 32-39, 43 and 44, which show one embodiment of the apparatus and method for bending the straight blank 200 into the bent blank 262 of FIGURE 40.

The apparatus 219, FIGURE 32, for bending the blank 20!) of FIGURES 32 and 40 into the bent blank 202 of FIGURES 34 and 40, and for practicing a corresponding method for forming a bumper, may include a center pressing member 226 having a center pressing member groove 222 of FIGURES 32, 35 and 38 to receive, in initial position, the substantially straight, groove shaped, bumper blank 260 of FIGURE 40, and which has the general cross section shown in FIGURE 41. The bumper blank 2% is placed in the groove 222 with its ends 224 extending beyond the pressing member 220. A pair of rocker members 226 are located respectively at each end of the pressing member 226, and have a rocker member groove 228 of It? FIGURES 32 and 37 which are aligned in initial position, with the pressing member groove 222 to receive the ends 224 of the bumper blank 2%.

If desired, the apparatus shown in FIGURE 32 may be one of a pair of substantially identical apparatuses shown in FIGURE 39.

A punch member 232 has a central ridge member 234 relatively movable into the pressing member groove 222 to hold the bumper blank 2% in the pressing member groove 222. The punch member 232 also has a pair of punch side ridge members 236 respectively at each end of the central ridge member 234 and at an angle thereto, such as a right angle, with a curved portion 238 joining the end ridge members 236 to the central ridge member 2254.

Means are provided, and are shown in FIGURES 33, 34 and 40, to cause relative movement between the center pressing memebr 220 and the rocker members 226 to bend the bumper blank ends 224 at an angle to the central portion 214 of the bumper blank, with the ends 224 being joined by a curved portion 240. The punch holder 246 carries the punch 232 and moves it into contact with the center pressing member 220 while the punch end ridge members 236 contact the inside ends 235, FIGURE 32 of the rocker members 226 to cause them to turn about the fulcrums 248 from their initial aligned or level positions, which are shown in FIGURE 32, to a substantially perpendicular position with the ends 224 as shown in FIGURE 34. This bending operation is illustrated also in FIGURE 40, with the straight position in dotted lines and the bent position in full lines.

The pressing operation is such that the punch 232 moves down until the lower, central ridge member 234, FIGURE 38, is snugly within the groove 214 of the bumper blank 2% which, in turn, is within the groove 222 of the center presure member 220. The curved punch portions 238 at the ends of the central ridge member 234 extend sufliciently far initially to extend into the ends 235 of the rocker members 226 and into contact with the groove 214 of the bumper blank 260. At this time the bumper blank 266 is still in a relatively straight condition. However, with a further downward movement of the punch 232, FIGURE 33, the rocker members 226 start to turn about the fulcrums 248, so that gradually the curved portion 238 and the end ridge member construction 236 finally bring the rocker members 226 into vertical position, FIGURE 34, to bend the straight blank 224 of FIG- URE 32 into the bent blank 224 of FIGURE 34, substantially at right angles to the straight central portion 214. The results of this motion is shown in FIGURE 40 in which the dotted line blank straight ends 224 are bent into full line ends 212.

The downward movement of the punch 232, FIGURE 34, continues until the end ridge members 236 enter the re-strike grooves 252 in the restrike dies 254. The re-strike dies 254 are stationarily held or mounted on the stationary die shoe 256. The re-strike grooves 252 smooth out any corrugations that might be formed at the bends 246, FIGURES 40 and 34.

The fulcrums, or pivot pins 248, may be mounted on pedestals 258, which, in turn, may be mounted on the restrike die 254 to hold the fulcrums 248 in stationary position.

Means are provided t-o strike a license plate formation 264, FIGURE 40, in the bumper blank 202. To this end, a stationary license plate die 262 in FIGURES 32-36 is mounted on the die shoe 256. The license plate die 262 has a flat face 264, with a curved upper end 266 in FIGURE 36, to flatten the larger wing 215 in FIG- URE 41 of the blank 262 into a license plate receptacle 204, of FIGURE 40. The smaller wing 215a remains substantially unbent. The license plate die 262 is encompassed in the opening 268 of FIGURE 35 in the center pressing member 226 when the member 220 nears its lowest point of travel. The punch 232 has an indentation 270, FIG- 

1. A BLANK FOR AN ALUMINUM CONTAINING METALLIC AUTOMOTIVE VEHICLE BUMPER FORMED FROM AN IRREGULARLY CROSSSECTIONED EXTRUSION. 